U.S. patent number 5,896,293 [Application Number 08/821,077] was granted by the patent office on 1999-04-20 for method of managing information exchanged between production information supervisory computer and line supervisory computers for production of photo film cartridge.
This patent grant is currently assigned to Fuji Photo Film Co., Ltd.. Invention is credited to Nobuyasu Akiyoshi, Susumu Sato, Hiroshi Seikai, Junichi Teramoto.
United States Patent |
5,896,293 |
Teramoto , et al. |
April 20, 1999 |
Method of managing information exchanged between production
information supervisory computer and line supervisory computers for
production of photo film cartridge
Abstract
Supervisory computers are individually disposed in a molding
line for molding a pair of shell halves, a cartridge assembly line
for assembling a cartridge shell from the pair of shell halves and
other parts, a winding line for producing and winding each
individual filmstrip into each individual cartridge shell, a
packaging line for packaging the photo film cartridges, and those
of other lines or other processes. Each supervisory computer
controls process controllers of the associated line. The
supervisory computers are controlled by a production information
supervisory computer. Data obtained from the process controllers is
sent through the line supervisory computers to the production
information supervisory computer, to be stored therein.
Inventors: |
Teramoto; Junichi (Kanagawa,
JP), Seikai; Hiroshi (Kanagawa, JP),
Akiyoshi; Nobuyasu (Kanagawa, JP), Sato; Susumu
(Kanagawa, JP) |
Assignee: |
Fuji Photo Film Co., Ltd.
(Kanagawa, JP)
|
Family
ID: |
13330487 |
Appl.
No.: |
08/821,077 |
Filed: |
March 20, 1997 |
Foreign Application Priority Data
|
|
|
|
|
Mar 22, 1996 [JP] |
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8-066939 |
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Current U.S.
Class: |
700/111; 396/207;
355/40; 242/532.4; 242/532.5; 700/95; 700/109; 700/115 |
Current CPC
Class: |
G05B
19/41865 (20130101); G05B 2219/32412 (20130101); G05B
2219/31426 (20130101); Y02P 90/02 (20151101); G05B
2219/31428 (20130101); G05B 2219/32191 (20130101) |
Current International
Class: |
G05B
19/418 (20060101); G06F 019/00 (); G06G 007/64 ();
G06G 007/66 () |
Field of
Search: |
;364/468.01,468.04,468.06,468.8,468.09,468.16,468.18,468.22,468.23,468.24,469.01
;242/532.4,332.7,348.1,532.5,532.6,532.7
;29/430,417,429,779-783,819 |
References Cited
[Referenced By]
U.S. Patent Documents
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|
|
4561235 |
December 1985 |
Yanagisawa et al. |
5229585 |
July 1993 |
Lemberger et al. |
5255197 |
October 1993 |
Iida |
5447827 |
September 1995 |
Ishikawa et al. |
5479691 |
January 1996 |
Shimizu et al. |
5573201 |
November 1996 |
Takahashi et al. |
5584441 |
December 1996 |
Watkins et al. |
|
Foreign Patent Documents
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|
|
|
|
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6-130548 |
|
May 1994 |
|
JP |
|
7-120889 |
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May 1995 |
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JP |
|
Primary Examiner: Grant; William
Assistant Examiner: Patel; Ramesh
Attorney, Agent or Firm: Sughrue, Mion, Zinn, Macpeak &
Seas, PLLC
Claims
What is claimed is:
1. A method of managing information for production of a plurality
of different types photo film cartridges, wherein a first
production line for produces cartridge shells and a second
production line produces and winds filmstrips individually into
said cartridge shells to produce said photo film cartridges, said
method comprising the steps of:
A. providing production plan data to a production information
supervisory computer, said production plan data designating a
particular type and a requisite number of photo film cartridges to
produce;
B. preparing a first set of production order data for producing
cartridge shells of said particular type photo film cartridges, and
a second set of production order data for producing and winding
filmstrips of said particular type photo film cartridges, based on
said production plan data in said production information
supervisory computer;
C. sending said first and said second set of production order data
from said production information supervisory computer to first and
second line supervisory computers respectively;
D. controlling said first production line by said first line
supervisory computer in accordance with said first set of
production order data;
E. controlling said second production line by said second line
supervisory computer in accordance with said second set of
production order data; and
F. sending feedback data obtained from said first and second
production lines to said production information supervisory
computer through said first and second line supervisory computers
respectively, to control said first and second line supervisory
computers so that said first and second supervisory computers
cooperate with each other through said production information
supervisory computer.
2. A method as claimed in claim 1, wherein there is a third
production line for packaging said photo film cartridges, said
method further comprising the steps of:
preparing a third set of production order data based on said
production plan data in said production information supervisory
computer;
providing said third set of production order data from said
production information supervisory computer to a third line
supervisory computer;
controlling said third production line by said third line
supervisory computer in accordance with said third set of
production order data; and
providing feedback data obtained from said third production line
through said third line supervisory computer to said production
information supervisory computer, to control said third line
supervisory computer to cooperate with said first and second line
supervisory computers by said production information supervisory
computer.
3. A method as claimed in claim 2, further comprising the steps
of:
generating, when a malfunction is detected in any of said
production lines, or when a defection is detected of any of
products or semi-products in any of said production lines,
defection data from a corresponding one of said line supervisory
computers to said production information supervisory computer;
storing said defection data in said production information
supervisory computer; and
sending a command from said production information supervisory
computer to said line supervisory computers, to eliminate those
products or semi-products having said defection from said
production lines.
4. A method as claimed in claim 1, further comprising the steps
of:
preparing a prescription table for one of said plurality of
different types of photo film cartridge types, said prescription
table designating material types to supply to said first and second
production lines and production conditions setup in said first and
second production lines for said one photo film cartridge type;
storing said prescription tables in said production information
supervisory computer;
storing material stock data about stocked amounts of respective
type materials in said production information supervisory computer;
and
revising said material stock data each time said materials are
stocked or fed out;
wherein step B comprises the steps of:
determining, in response to said production plan data, the types
and necessary amounts of materials to supply to said first and
second production lines for producing said requisite number of said
particular type photo film cartridges with reference to one of said
prescription tables that is assigned to said particular type;
collating the necessary amount with the stocked amount for each of
said determined type materials with reference to said material
stock data;
integrating all data necessary for producing said particular type
photo film cartridges in accordance with said production plan data,
into a common production order table;
producing first and second individual production order tables from
said common production order table, said first individual
production table consisting of those data pieces which are
necessary for operating said first production line, said second
individual production tables consisting of those data pieces which
are necessary for operating said second production lines; and
wherein step C further comprises:
sending said first and second individual production order tables to
said first and second line supervisory computers respectively.
5. A method as claimed in claim 4, further comprising the steps
of:
storing said common production order table in said production
information supervisory computer; and
storing said feedback data from said first and second line
supervisory computers in association with said common production
order table.
6. A method as claimed in claim 5, wherein said feedback data
includes at least one of performance data and production history
data, said performance data indicating the numbers of products and
semi-products produced in each of said production lines, and the
number of rejected products or rejected semi-products, said
production history data including the types or production lot
numbers of materials actually supplied to each of said production
lines.
7. A method as claimed in claim 6, wherein said production history
data further includes environmental condition data representing
environmental temperature, moisture and cleanness of each of said
production lines, and operational condition data representing
supply voltage, supply air pressure and supply oil pressure used
for operating each of said production lines.
8. A method of managing information for production of a plurality
of different types photo film cartridges, wherein a first
production line produces cartridge shells and a second production
line produces and winds filmstrips individually into said cartridge
shells to produce said photo film cartridges, said method
comprising the steps of:
A. providing production plan data to a production information
supervisory computer;
B. controlling said first and second production lines in accordance
with said production plan data through first and second line
supervisory computers respectively;
C. determining a range of cartridge ID numbers based on said
production plan data in said production information supervisory
computer;
D. determining a range of film ID numbers in correspondence with
said determined cartridge ID numbers in said production information
supervisory computer;
E. sending data of determined cartridge ID numbers and data of
determined film ID numbers to said first and second line
supervisory computers respectively;
F. providing a cartridge ID number on each individual cartridge
shell being produced in said first production line in accordance
with the data of determined cartridge ID numbers;
G. providing a film ID number on each individual filmstrip being
produced in said second production line in accordance with the data
of determined film ID numbers;
H. reading cartridge ID numbers from said cartridge shells when
said cartridge shells are being combined with said filmstrips in
said second production line; and
I. collating said read cartridge ID numbers with said determined
film ID numbers in said second line supervisory computer to confirm
correspondence between said read cartridge ID numbers and said
determined film ID numbers.
9. A method as claimed in claim 8, wherein step F comprises the
steps of:
supplying labels with the same range of ID numbers thereon as said
determined cartridge ID numbers to a labeling machine disposed in
said first production line; and
attaching said labels seriatim to said cartridge shells.
10. A method as claimed in claim 9, wherein one of said determined
film ID numbers is provided on one of said filmstrips after it is
confirmed that one of said cartridge shells that is being combined
with said one filmstrip has a corresponding cartridge ID number to
said one film ID number.
11. A method as claimed in claim 10, wherein a film ID number is
printed on a side portion of said each individual filmstrip by a
printer having a head consisting of an array of photo emission
diodes, and wherein said method further comprising the steps
of:
detecting current patterns of drive signals supplied to said photo
emission diodes;
deriving from said current patterns printed film ID numbers
actually printed on said filmstrips;
collating said printed film ID numbers with said determined film ID
numbers which are determined by said production information
supervisory computer, or with said read cartridge ID numbers which
are read from said cartridge shells in said second production
line.
12. A method as claimed in claim 11, wherein the range of said
determined cartridge ID numbers coincides with the range of said
determined film ID numbers.
13. A method as claimed in claim 8, further comprising the steps
of:
providing feedback data obtained from said first and second
production lines to said production information supervisory
computer through said first and second line supervisory computers
respectively, to control said first and second line supervisory
computers so that said first and second supervisory computers
cooperate with each other through said production information
supervisory computer; and
storing said feedback data in association with said read cartridge
ID numbers.
14. A method as claimed in claim 13, wherein said feedback data
includes performance data and production history data, said
performance data indicating the numbers of products and
semi-products produced in the respective production lines, and the
number of rejected products or rejected semi-products, said
production history data including the types or production lot
numbers of materials actually supplied to the respective production
lines.
15. A method as claimed in claim 14, wherein there is a third
production line for packaging said photo film cartridges, said
method further comprising the steps of:
providing package ID numbers on individual packaging materials
before having said photo film cartridges packaged therein;
correlating said package ID numbers of said individual packaging
materials with cartridge ID numbers of said packaged photo film
cartridges respectively by a third line supervisory computer
controlling said third production line;
sending said package ID numbers being correlated with said
cartridge ID numbers to said production information supervisory
computer from said third line supervisory computer; and
storing said package ID numbers in said production information
supervisory computer along with said feedback data in association
said cartridge ID numbers.
16. A method as claimed in claim 15, wherein every predetermined
plural number of said packaged photo film cartridges are packed in
a box, said method further comprising the steps of:
providing a box ID number on each box;
correlating said box ID number with package ID numbers of those
packaged photo film cartridges which are packed in said each
box;
storing said correlation between said box ID number and said
package ID numbers in said production information supervisory
computer.
17. A method of managing information for production of a plurality
of different types photo film cartridges, wherein a first
production line produces cartridge shells and a second production
line produces and winds filmstrips individually into said cartridge
shells to produce said photo film cartridges, said method
comprising the steps of:
A. providing production plan data to a production information
supervisory computer;
B. controlling said first and second production lines in accordance
with said production plan data through first and second line
supervisory computers respectively;
C. determining a range of cartridge ID numbers based on said
production plan data in said production information supervisory
computer;
D. supplying labels with the same range of ID numbers thereon as
the range of said determined cartridge ID numbers to said second
production line;
E. attaching said labels to said cartridge shells when supplied to
said second production line from said first production line;
F. reading individual ID numbers from said labels in said second
production line;
G. printing a film ID number that coincides with one of said read
ID numbers onto a side portion of one of said filmstrips being
produced in said second production line; and
H. before or after said one filmstrip is wound into one of said
cartridge shells, collating said printed film ID number with the ID
number of the label attached to said one cartridge shell.
18. A method as claimed in claim 17, wherein film ID numbers are
printed on said filmstrips by a printer having a head consisting of
an array of photo emission diodes, and wherein step H comprising
the steps of:
detecting current patterns of drive signals supplied to said photo
emission diodes while said printer effects printing on said one
filmstrip;
deriving from said current patterns said printed film ID
number;
collating said printed film ID number with the cartridge ID number
which is read from said one cartridge shell.
19. A method as claimed in claim 18, further comprising the steps
of:
providing feedback data obtained from said first and second
production lines to said production information supervisory
computer through said first and second line supervisory computers
respectively, to control said first and second line supervisory
computers so that said first and second supervisory computers
cooperate with each other through said production information
supervisory computer; and
storing said feedback data in association with said read cartridge
ID numbers.
20. A method as claimed in claim 19, wherein said feedback data
includes performance data and production history data, said
performance data indicating the numbers of products and
semi-products produced in the respective production lines, and the
number of rejected products or rejected semi-products, said
production history data including the types or production lot
numbers of materials actually supplied to the respective production
lines.
21. A method as claimed in claim 20, wherein there is a third
production line for packaging said photo film cartridges, said
method further comprising the steps of:
providing package ID numbers on individual packaging materials
before having said photo film cartridges packaged therein;
correlating said package ID numbers of said individual packaging
materials with cartridge ID numbers of said packaged photo film
cartridges respectively by a third line supervisory computer
controlling said third production line;
sending said package ID numbers being correlated with said
cartridge ID numbers from said third line supervisory computer to
said production information supervisory computer; and
storing said package ID numbers in said production information
supervisory computer along with said feedback data in association
said cartridge ID numbers.
22. A method as claimed in claim 21, wherein every predetermined
plural number of said packaged photo film cartridges are packed in
a box, said method further comprising the steps of:
providing a box ID number on each box;
correlating said box ID number with package ID numbers of those
packaged photo film cartridges which are packed in said each
box;
storing said correlation between said box ID number and said
package ID numbers in said production information supervisory
computer.
23. A method of managing information for production of a plurality
of different types photo film cartridges, wherein a first
production line produces cartridge shells, and a second production
line produces and winds filmstrips individually into said cartridge
shells to produce said photo film cartridges, and wherein said
filmstrips are cut from a continuous strip in said second
production line, and a plurality of said continuous strips are
formed by slitting a wider web of photo film, said method
comprising the steps of:
controlling said first production line by a first line supervisory
computer in accordance with production order data from an
information supervisory computer;
controlling said second production line by a second line
supervisory computer in accordance with production order data from
said information supervisory computer;
controlling said slitting process by a fourth supervisory
computer;
generating defect data in said fourth supervisory computer when a
temporary disorder is detected in said slitting process or a
defective portion is detected in one of said continuous strip, said
defect data including identification data of a roll of wider web
which is subjected to said slitting process at the time of said
disorder, or from which said one continuous strip having said
defective portion is formed, slit position data representative of
an original position of said one continuous strip in a lateral
direction of said wider web, and position data of said defective
portion in a longitudinal direction of said one continuous
strip;
storing said defection data from said fourth supervisory computer
in said production information supervisory computer;
monitoring advanced length of said continuous strip in said second
production line; and
controlling said cutting process of said continuous strip based on
said advanced length and said defection data such that said
defective portion is cut out to be eliminated from said second
line.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an information management method
for managing information about production or manufacture of photo
film cartridges, each of which contains a roll of photo filmstrip
in a light-tight cartridge shell. More particularly, the present
invention relates to a production information management method, by
which the operation of production facilities for the photo film
cartridges is efficiently controlled, and various kinds data
obtained from these facilities are efficiently utilized for
manufacturing the photo film cartridges.
2. Background Arts
Photo film cartridge containing a roll of photo filmstrip in a
light-tight cartridge shell are widely used for photography. The
photo film cartridges can be sorted into various types according to
the film speed, the number of available exposures, whether it is a
color film or a black-and-white film, etc., so that photographers
may chose appropriate types in accordance with their needs or
intentions. To show the type of each photo film cartridge,
information or indicia is printed on the cartridge shell and on the
packaging casket, e.g. a cardboard box. The indicia on the casket
and the cartridge shell must precisely indicate the type of photo
filmstrip contained therein. Accordingly, it is necessary to
supervise the production process of the photo film cartridges so as
to prevent confusion between different type parts, that is, prevent
combining a filmstrip with a different type cartridge shell or a
different type casket.
For such production management, papers, e.g. slips, labels and
books, have been popularly used. First when manufacturing the
filmstrip, an emulsion, whose type is determined according to a
production plan, is applied on one surface of a wide web of base
film, to produce a master roll. Next the master roll is slit into
continuous strips of a constant width. The continuous strips are
each individually formed into a roll, and a label is attached to
the roll, indicating the number of the emulsion used, the
production date and time, the production lot number and other data
about the rolled continuous strip. On the other hand, the cartridge
shells and the caskets are produced with indicia indicating a film
cartridge type determined according to the production plan. The
productions are collected in containers according to the kind of
parts, the production date, and the production lot number. A label
indicating the production date and the production lot number is
attached to each container in the same way as the productions.
Since the film cartridge type is assigned to the respective parts,
i.e., the continuous strips, the cartridge shells and the caskets,
in the respective production stages, it is possible to correlate
the film cartridge type with the production lot numbers of the
respective parts, for example, by use of a parts management table.
Thereby, the production management department can designate the
film cartridge type to produce by the production lot numbers of the
respective parts. With reference to the production lot numbers on a
production order slip issued by the production management
department, the manufacture department can chose an appropriate
kind of parts by identifying the production lot numbers indicated
by the labels on the containers. The chosen parts are supplied to
the respective production apparatuses on the manufacture lines.
In order to improve the efficiency of the paper-based production
management, the way to utilize computers for the production
management has been studied. Generally, production facilities for
photo film cartridges consist of a plurality of manufacture lines.
Therefore, disposing a line supervisory computer in each of the
manufacture lines make it possible to check if the parts supplied
to each line are proper or not. By entering data of the production
lot numbers of the parts and production conditions into the line
supervisory computers with reference to the production order slips
issued from the production management department, it is possible to
check the production lot number of the parts as being supplied to
each production apparatus, or setup conditions of each production
apparatus prior to actuation.
The production conditions include production conditions and
inspection conditions. As examples of the production conditions,
the length of individual filmstrips to be cut from the continuous
strip, and side-printing format for printing an ID number and frame
serial numbers on the sides of each individual filmstrip are
designated according to the type and the number of available
exposures of the photo film cartridges to produce. As the
inspection conditions, there are threshold data for appearance
tests and performance tests, timing data and sampling number data
for sampling inspection, and so forth.
The setup data of the production conditions and the inspection
conditions used for each kind of parts is entered in the books
along with the production date data. Alternatively, hard copies of
the setup data are printed out from a terminal computer, and are
stored with the books. This allows to trace the records or history
of any photo film cartridge after the shipment, such as the
production conditions and the inspection conditions used for the
photo film cartridge, if only the production lot number is
determined. Therefore, storing the setup data in or with the books
is very useful for the quality management or supervisory. After
storing the setup data, the production apparatuses are actuated to
manufacture and pack the photo film cartridges in accordance with
production order table.
Recently, a new type photo film cartridge, called IX 240 type or
Advanced Photo System type, was brought into market. The new type
uses completely different cartridge shell and filmstrip from those
of the conventional ISO 135 type. The new cartridge shell is
constituted of a pair of plastic shell halves, a spool, a light
shielding door and other plastic parts, and functions such that the
leader of the filmstrip fully wound into the cartridge shell is
advanced out of the cartridge shell responsive to unwinding
rotation of the spool.
As described above, when manufacturing various types photo film
cartridges, parts management is necessary to sort the parts and the
packages of the photo film cartridges and chose correct parts and
packages in accordance with the film cartridge type. Especially in
the production facilities for IX 240 type photo film cartridge,
which consists of a lot of parts and some of them vary depending
upon the filmstrip format, the parts management can be complicated.
According to the conventional paper-based production management
method, management of an increasing number of papers themselves can
be time- and labor-consuming: It is necessary to write setup data
in the papers along with the other production information, or
preserve hard copies of setup data in association with the papers
containing other information. The operators can misread the
information on the papers, especially when the film cartridge type
to produce should be changed on a manufacture line.
Regarding the setup of the production conditions and the inspection
conditions on the line supervisory computers in the respective
manufacture lines, data input operation can be time- and
labor-consuming, as the number of film cartridge types increases,
or as the installation number of production apparatuses increases
for a larger scale of mass-production. Moreover, when to change the
production conditions or the inspection conditions, that is often
necessary if any parts are disqualified in an inspection step,
manual revising of the setup data in the line supervisory computers
is also time- and labor-consuming, and can cause setup errors.
In addition, since IX 240 type photo film cartridges after
development are expected to be returned to the photographer with
the developed filmstrip rewound into the same cartridge shell as
before, each cartridge shell is provided with the same ID number as
the filmstrip contained therein. Accordingly, it is necessary to
correlate the ID numbers of the filmstrips with those of the
cartridge shells precisely one by one during the manufacture. To
make this correlation on the conventional paper-based system is
extremely time- and labor-consuming, and lacks reliability. A
single computer supervising the entire manufacture lines involves
disadvantages like longer data processing time and slower response
with the increasing number of manufacture lines or manufacture
steps or parts of the article.
SUMMARY OF THE INVENTION
In view of the foregoing, a primary object of the present invention
is to provide a production information management method for the
manufacture lines which are used for manufacturing and packaging
various types photo film cartridges, wherein confusion between
different type parts is prevented by an efficient parts management,
production management information obtained during the manufacture
is collected and stored with accuracy, and ID numbers are given to
the filmstrips, the cartridge shells and the caskets to permit
one-to-one correlation between these elements without the need for
complicated production process.
To achieve the above and other objects and advantages, the present
invention provide a method of managing information about production
of various types photo film cartridges, wherein there is a first
production line for producing cartridge shells and a second
production line for producing and winding filmstrips individually
into the cartridge shells to produce the photo film cartridges, the
method comprising the steps of:
feeding production plan data in a production information
supervisory computer, the production plan data designating a
particular type and a requisite number of photo film cartridges to
produce;
preparing a first set of production order data for producing
cartridge shells of the particular type photo film cartridges, and
a second set of production order data for producing and winding
filmstrips of the particular type photo film cartridges, based on
the production plan data in the production information supervisory
computer;
sending the first and the second set of production order data to
first and second line supervisory computers respectively;
controlling the first production line by the first line supervisory
computer in accordance with the first set of production order
data;
controlling the second production line by the second line
supervisory computer in accordance with the second set of
production order data; and
sending feedback data obtained from the first and second production
lines to the production information supervisory computer through
the first and second line supervisory computers respectively, to
control the first and second line supervisory computers to
cooperate with each other by the production information supervisory
computer.
To correlate ID numbers of the cartridge shells with ID numbers on
the filmstrips, the present invention provides the steps of:
feeding production plan data in a production information
supervisory computer;
controlling the first and second production lines in accordance
with the production plan data through first and second line
supervisory computers respectively;
determining a range of cartridge ID numbers based on the production
plan data in the production information supervisory computer;
determining a range of film ID numbers in correspondence with the
determined cartridge ID numbers in the production information
supervisory computer;
sending data of determined cartridge ID numbers and data of
determined film ID numbers to the first and second line supervisory
computers respectively;
providing a cartridge ID number on each individual cartridge shell
being produced in the first production line in accordance with the
data of determined cartridge ID numbers;
providing a film ID number on each individual filmstrip being
produced in the second production line in accordance with the data
of determined film ID numbers;
reading cartridge ID numbers from the cartridge shells when the
cartridge shells are being combined with the filmstrips in the
second production line; and
collating the read cartridge ID numbers with the determined film ID
numbers in the second line supervisory computer, so as to confirm
correspondence between the read cartridge ID numbers and the
determined film ID numbers.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the present invention
will become apparent from the following detailed description of the
preferred embodiments when read in connection with the accompanying
drawings, which are given by way of illustration only and thus are
not limitative of the present invention, wherein like reference
numerals designate like or corresponding parts throughout the
several views, and wherein:
FIG. 1 is an exploded perspective view of a IX 240 type photo film
cartridge and its packaging materials;
FIG. 2 is a functional block diagram illustrating the overall
production processes of the photo film cartridges of IX 240
type;
FIG. 3 is a block diagram illustrating data communications between
computers and process controllers in the production facilities of
the photo film cartridges;
FIG. 4 is an explanatory view illustrating data formats of data fed
in and fed out a production information supervisory computer;
FIG. 5 is a functional block diagram illustrating processes for
producing cartridge shells;
FIG. 6 is a function block diagram illustrating processes for
completing and packaging the photo film cartridges; and
FIG. 7 is a schematic diagram illustrating a film winding line for
producing and winding filmstrips into the cartridge shells.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an IX 240 type photo film cartridge, wherein a photo
filmstrip 2 has a width specific to IX 240 type, and a length
determined in accordance with the number of available exposures. A
pair of perforations 2a are allocated to each frame such that a
picture frame is photographed in a position shown by phantom lines.
A fastening hole 3 and a pair of hooking holes 4 are formed through
a trailing end of the filmstrip 2, at which the filmstrip 2 is
fastened to a spool 6 of a cartridge shell 5.
The cartridge shell 5 consists of a pair of plastic integral shell
halves 5a and 5b, the spool 6 rotatably mounted in between the
shell halves 5a and 5b, a light shielding door 7, a data disc 8,
and other parts which constitute leader-advancing and spool-locking
mechanisms.
The light shielding door 7 is to open and close a film port 9 of
the cartridge shell 5. When fastening the filmstrip 2 to the spool
6, the hooking holes 4 are hooked on a not-shown film inserter
which is a movable blade with hooks, and the light shielding door 7
is opened to let the film inserter into the cartridge shell 5
through the film port 9. Then, the fastening hole 3 is engaged with
a not-shown retaining claw formed on the spool 6. After the
inserter is removed, the spool 6 is rotated in a winding direction
to wind the filmstrip 2 into the cartridge shell 5. When the entire
length of the filmstrip 2 has been wound up, the light shielding
door 7 is closed to shield the interior of the cartridge shell 5
from light. This winding process is performed in a dark room. The
film inserter is disclosed in more detail, e.g., in JPA 7-120889
and U.S. Pat. No. 5,573,201.
The photo film cartridge manufactured in this way is put into a
plastic case 11, which is sealed with a cap 11a in a moisture tight
fashion. The photo film cartridge in the plastic case 11 is
packaged in a cardboard or plastic casket 13 for sale. A label 15
is attached to the periphery of the cartridge shell 5. The label 15
is provided with literal indicia 16 about the film cartridge type
such as the film type, the film speed, the number of available
exposures, color or monochrome, and other necessary information.
The label 15 further has a bar code 17 representative of an ID
number of the cartridge shell 5. The cartridge ID number is to
coincide with a film ID number which is recorded as a photographic
latent image on a given side portion 2b of the filmstrip 2.
The casket 13 has literal indicia 18 about the film cartridge type,
and bar codes 19a and 19b printed thereon. The photographer can see
the film cartridge type and other necessary information from the
literal indicia 16 and 18. The bar code 19a represents a package ID
number which is to coincide with the cartridge ID number.
Alphanumeric indicia of the package ID number is printed along with
the bar code 19a, so as to permit visual confirmation of the
package ID number. Also, alphanumeric indicia of the cartridge ID
number is printed along with the bar code 17 for the visual
confirmation of the cartridge ID number, though it is omitted from
the drawings. The other bar code 19b represents the film cartridge
type like the literal indicia 16 and 18, so as to permit automatic
reading the film cartridge type in the factory.
FIG. 2 schematically shows the overall process from the manufacture
to the shipment of the above photo film cartridge. A master roll is
formed by coating a surface of a wide base film with a
predetermined emulsion. A production lot number and the number of
the emulsion are provided on the reel of the master roll or on the
outer end of the master roll in the form of a bar code or magnetic
data. The master roll is supplied to a slitter 21, to be slit into
several, e.g. four, continuous strips of the same width as the
filmstrip 2. The continuous strips are respectively wound into
rolls, hereinafter referred to as slit rolls. A label is attached
to the reel and/or the outer end of each slit roll. On the label, a
slit number indicating the original location of the slit roll in
the crosswise direction of the master roll, the master roll lot
number and the emulsion number are printed or magnetically
recorded. The slit rolls produced from the same master roll are
loaded in an automatic vehicle in a light-tight fashion, and these
vehicles are stored in a dark storage section 29.
When manufacturing the cartridge shell 5, resin pellets of raw
material are supplied to molding machines 22 and 23, which form the
shell halves 5a and 5b as integral parts, respectively. The shell
halves 5a and 5b, and other parts, including the spools 6, the
light shielding doors 7, the labels 15, are sequentially supplied
to a cartridge assembly line 24, to be assembled into the cartridge
shells 5. These parts are loaded on parts-trays in the production
lots, and the trays are sequentially supplied to the cartridge
assembly line 24. The assembled cartridge shells 5 are loaded on
shell-trays in a given number lots, and the shell-trays are
stacked. Each individual tray has a tray ID number which is
correlated to the production lot number of each part. Therefore, it
is possible to trace the production history data of the cartridge
shells 5, i.e. the respective production lot numbers of the parts
of the cartridge shells 5, on the basis of the tray ID numbers,
before the winding of the filmstrips 2.
The slit rolls and the cartridge shells 5 are supplied to a film
winding line 25. The film winding line 25 forms the perforates 2a
in the continuous strip, prints data on the sides of the continuous
strip, and then cuts the continuous strip at the length determined
depending upon the number of available exposures of the individual
filmstrips 2 to produce. At the cutting, the shapes of the leading
and trailing ends of the filmstrips 2 are formed, and the fastening
hole 3 and the hooking holes 4 are punched through the trailing
end.
In the film winding line 25, the trailing end of the filmstrip 2 is
headed toward the cartridge shell 5 which is placed in a given
position. The film inserter is actuated to fasten the trailing end
of the filmstrip 2 to the spool 6. Thereafter, the spool 6 is
rotated to wind up the filmstrip 2 completely into the cartridge
shell 5. By closing the light shielding door 7, the photo film
cartridge is finished as a product. Then, the photo film cartridge
is supplied to a packaging line 27, to be packaged with the plastic
case 11 and the casket 13. The caskets 13 containing the photo film
cartridges are wrapped up in cellophane sheet and/or packed in
corrugated cardboard boxes in groups of a given number, for
shipment. Some types photo film cartridges are encased in pairs or
in groups of three or more in larger size caskets.
In order to permit choosing the parts in the respective processes
efficiently and properly in accordance with the production plan or
order, and retrieving the production history data of the individual
photo film cartridges accurately based on the respective ID
numbers, the respective production apparatuses, i.e. the slitter
21, the molding machines 22 and 23, the cartridge assembly line 24,
the film winding line 25 and the packaging line 27, are totally
managed by a production information supervisory computer 35, as is
shown in FIG. 3.
In FIG. 3, a molding line supervisory computer 30, an assembly line
supervisory computer 31, and a film winding line supervisory
computer 32 are line supervisory computers provided for controlling
the respective production apparatuses each individually. In the
molding machine 23, for example, it is necessary to perform a
plurality of processes in a sequential fashion: supplying raw
material, heating, injection, cooling and removal from the mold.
Process controllers 30a, 30b, 30c . . . are provided for
maintaining these processes under proper conditions, and control
the raw material supply amount, the temperature, the injection
pressure, the cooling time, the mold removal speed and so forth in
response to commands from the molding line supervisory computer
30.
In the cartridge assembly line 24, pallets are successively
circulating around the cartridge assembly line 24, and each pallet
receives one of the shell halves 5b supplied from the molding
machine 23. While the pallet makes one cycle, other parts such as
the spool 6, the light shielding door 7 and the shell half 5a from
the molding machine 22 are sequentially mounted to the shell half
5b on the pallet, and the label 15 is attached to the cartridge
shell 5. In order to perform these processes properly, process
controllers 31a, 31b, 31c . . . control the conveying speed of the
pallets, and control actuators of robotics, e.g. motors, air
cylinders and oil cylinders.
In the film winding line 25, the continuous strip is withdrawn from
the slit roll at a constant speed, and is transported through a
perforator and a side-printer. Thereafter, the continuous strip is
cut into the filmstrips 2. On the other hand, the cartridge shells
5 are set in a turn table, so that the filmstrips 2 are seriatim
fastened to the spools 6 of the cartridge shells 5 by use of the
film inserter, and are wound up into the respective cartridge
shells 5. These winding steps are respectively controlled by
process controllers 32a, 32b, 32c . . . in response to commands
from the film winding line supervisory computer 32.
In this way, the line supervisory computers 30 to 32 constitute
interprocess networks with the process controllers within the
respective manufacture lines, to manage the respective processes to
be carried out properly in the individual production apparatuses.
In addition, data obtained through the process controllers is fed
back to the line supervisory computer 30, 31 or 32, and is stored
in a respective memory 30x, 31x or 32x for each manufacture line.
The data obtained through the process controllers includes
performance data and inspection data, e.g. the number of assembled
products or semi-products, the number of qualified products, the
number of disqualified products, and other data obtained through
those process controllers which are used for controlling inspection
processes. Thereby, it is possible to monitor the data about
operational conditions of the respective processes of the
respective manufacture lines at any time through the line
supervisory computers 30, 31 and 32.
Like the molding line supervisory computer 30, the assembly line
supervisory computer 31 and the film winding line supervisory
computer 32, a line supervisory computer is disposed for each
manufacture line. These line supervisory computers are supervised
by the production information supervisory computer 35, so that they
constitute an inter-factory network. The production information
supervisory computer 35 provides production order information and
commands for setting up production conditions and inspection
conditions each individually to the line supervisory computers. For
this purpose, production plan data, stock plan data about flow-in
flow-out plans of the stocks of the respective materials, i.e. the
raw materials and the parts, and material stock data about the
actual stocks are fed in the production information supervisory
computer 35, and are stored in a memory 35x. The production plan
data and the stock plan data are entered through a keyboard of the
production information supervisory computer 35 or is read from a
recording medium like a magnetic disc. The material stock data may
be entered through the keyboard, or may be fed from the line
supervisory computers 30 to 32.
The memory 35x of the production information supervisory computer
35 previously stores prescription tables which are respectively
prepared for the potential photo film cartridge types to produce in
the factory. Each prescription table stores prescription data such
as the types of the materials and parts, production conditions and
inspection conditions necessary for producing a particular type
photo film cartridge. A product short name, which is given to each
film cartridge type, is written in the corresponding prescription
table.
The production information supervisory computer 35 produces a
common production order table upon receipt of production plan data.
Referring to FIG. 4, the production plan data includes the order
number, the product short name of the film cartridge type to
produce, the requisite number of cartridges to produce, and so
forth. The production information supervisory computer 35 retrieves
prescription data from the prescription table based on the product
short name, e.g. "AAAA", that is included in the production plan
data. Thus, the prescription type or number, the types and names of
the materials and parts, production conditions and inspection
conditions necessary for producing the photo film cartridge type
"AAAA" are determined.
After the types and names of the necessary materials and parts are
determined, the production information supervisory computer 35
accesses to the material stock data to display stock data on a
monitor screen, to permit checking if there are enough materials in
stock to produce the designated type photo film cartridges up to
the requisite production number designated by the production plan.
If any of the necessary materials is short in stock, the monitor
screen displays along with the production plan data the name of the
material in short and the shortage compared with the production
plan, and the maximum number of the photo film cartridges that can
be produced at present. The prescription table also stores header
data as supplementary data, e.g. the necessary mark-up of the
actual production number on the requisite production number, which
is to take the risk or estimated rejection rate and operating
factor into account.
When it is confirmed that the stock of all necessary materials is
sufficient, the production information supervisory computer 35
produces the common production order table. In the common
production order table, the prescription type, the production
number, the names of the materials to use, the production
conditions and the inspection conditions are assigned to an order
number and the product short name of the film cartridge type. Some
items are fixedly determined according to the film cartridge type,
and other items are variable. For example, the name and the
requisite number of each material are automatically determined by
the film cartridge type. The production lot numbers of the
respective materials and some of the production and inspection
conditions may be set up optionally. Thus, by designating their
production lot numbers, it is possible to choose those materials
which are determined to be optimum in view of their production
histories, so that a flexible measure can be taken for quality
stabilizing. These optionally variable items can be set up manually
in the production information supervisory computer 35 or through
the line supervisory computers. When the optional items are set up
through the line supervisory computers, the setup data is fed back
to the production information supervisory computer 35.
All the common production order tables are stored in the memory 35x
of the production information supervisory computer 35. The
production information supervisory computer 35 sorts out various
kinds data pieces in the common production order table, such as the
names of the materials selected and their production lot numbers,
the production conditions and the inspection conditions, for the
respective manufacture lines, and sends them along with the order
number, the product short name, the prescription type and the
production number to the line supervisory computers for the
respective manufacture lines. For example, the assembly line
supervisory computer 31 for controlling the cartridge assembly line
24 receives the names of the materials or parts to assemble the
cartridge shell 5 and their production lot numbers, and the
production conditions and the inspection conditions for the
cartridge assembly line 24 in the form of an individual production
order table. Then, the assembly line supervisory computer 31
displays the individual production order table on its monitor
screen, and sends commands to the respective sections of the
cartridge assembly line 24 to adapt to the determined production
and inspection conditions.
As described above, the production information supervisory computer
35 controls the respective line supervisory computers through the
inter-factory network, produces and stores common production order
tables in accordance with production plan data, produces individual
production order tables for the respective manufacture lines and
sends them to the corresponding line supervisory computers. After
the manufacture lines start operations, performance data is fed
from the manufacture lines back to the production information
supervisory computer 35, which then stores the performance data
along with the common production order table. Disposing of the line
supervisory computer in each manufacture line so as to give
separate functions from each other, and controlling the line
supervisory computers by the common production information
supervisory computer 35 permit high-speed precise data processing
without the need for an extreme load on a particular computer, and
also facilitate extending the manufacture lines.
Since the line supervisory computers are able to communicate with
the process controllers of the associated manufacture line in a
real time fashion, a quick response is possible to any requirement
for change in local conditions without the need for the production
information supervisory computer 35. In addition, it is possible to
display data on the monitor screen of each manufacture line in the
most convenient and efficient way. By connecting terminal
apparatuses to the inter-factory network, it is possible to access
to the production information supervisory computer 35 through the
terminal apparatus, it becomes possible to monitor the latest
production progress and the present production plan, as well as the
past production performance.
Since not only the operations of all the manufacture lines is under
the control of the production information supervisory computer 35,
but also the performance data and the production history data such
as the kind of materials used for processing and assembling and
their production lot numbers are fed back from the line supervisory
computers to the production information supervisory computer 35,
the production management department can totally control the
operations of all the manufacture lines, and can easily retrieve
the performance data from all the manufacture lines. Because the
production information supervisory computer 35 is accessible
through the line supervisory computers, it is possible to make good
use of experimental data obtained in practice in the production
department, for example, for setting up production conditions or
inspection conditions. Since the line supervisory computers receive
the individual production order tables from the production
information supervisory computer 35, and the fixed items are
automatically determined according to the production plan data, the
labor consumption is remarkably reduced compared with the
conventional method wherein setup data for the production
conditions is entered individually into each of the line
supervisory computers. Accordingly, man-caused failures or errors
are minimized.
Now, the information supervisory operation over the communication
between the molding line supervisory computer 30 and the assembly
line supervisory computer 31 and the respective production
apparatuses will be described with reference to FIG. 5. Among the
data contained in the common production order table produced in the
production information supervisory computer 35, those directed to
the molding machines 22 and 23 are sent as individual production
order tables to the molding line supervisory computer 30, and are
displayed on its monitor screen. The individual production order
tables include the amount and the production lot number of the raw
material to supply to each molding machine 22 or 23, so that the
raw material is automatically or semi-automatically thrown into
hoppers of the molding machines 22 and 23 in accordance with the
data in the individual production order tables.
Each container containing the raw material is provided with a bar
code representative of the production lot number of the raw
material, a resin type code and the like. The bar code is read by a
bar code reader prior to feeding the container to the molding
machine 22 or 23, and is sent to the molding line supervisory
computer 30. The 30 decodes the bar code to determine the
production lot number and compares it with the designated
production lot number. The result of comparison is sent with the
resin type code to the production information supervisory computer
35, to be stored as performance data.
The molding machines 22 and 23 work under those production
conditions designated by the individual production order table, to
form a requisite number of shell halves 5a and 5b, respectively.
The formed shell halves 5a or 5b are arranged in the order of being
formed on trays, a predetermined number for one tray. Every tray is
provided with an individual tray ID number as a bar code label or
in the form of magnetic data. The tray ID number is read in a
storage device 37 each time the storage device 37 receives the tray
with the predetermined number of shell halves 5a or 5b. The tray ID
number is sent from the storage device 37 to the 30. The 30
correlates the tray ID number with other production data pieces,
including the production date of the shell halves 5a or 5b arranged
on that tray, the production lot number and the resin type code of
the raw material and the production conditions used for these shell
halves 5a or 5b. The data thus obtained is sent with the order
number of the production plan data to the production information
supervisory computer 35, to be stored in the memory 35x.
The assembly line supervisory computer 31 manages the processes of
the cartridge assembly line 24 including an assembling machine 38,
a labeling machine 39 and a storage device 40 through the process
controllers 31a, 31b and 31c, which are incorporated into the
assembling machine 38, the labeling machine 39 and the storage
device 40, respectively. In the same way as for the molding line
supervisory computer 30, the production information supervisory
computer 35 inputs the individual production order table into the
assembly line supervisory computer 31. Each time the production
information supervisory computer 35 receives the tray ID number
data from the storage device 37, the production information
supervisory computer 35 sends the assembly line supervisory
computer 31 a tray ID number of the tray to be forwarded to the
assembling machine 38 next.
The assembly line supervisory computer 31 inputs a tray request
signal including the tray ID number into the assembling machine 38.
Then, the assembling machine 38 sends the tray request signal to an
automatic vehicle, so that the vehicle takes out the tray having
the designated tray ID number from the storage device 37, and
carries it to the assembling machine 38. The assembling machine 38
starts assembling the cartridge shell 5, while picking up the shell
halves 5a and 5b one by one from the trays.
In the same way as for the shell halves 5a and 5b, the spools 6,
the light-shielding doors 7 and other parts of the cartridge shell
5 are supplied to the assembling machine 38 from the respective
parts suppliers. The production lot numbers and the supply number
of these parts are determined and sent to the assembly line
supervisory computer 31 through the assembling machine 38. The
assembling machine 38 assembles these parts into the cartridge
shells 5 under the production conditions designated by the
individual production order table. The cartridge shells 5 are
subjected to an appearance inspection through a video inspection
device that is disposed in the assembling machine 38, and rejected
ones are eliminated.
Conditions for the appearance inspection, such as whether it is
total inspection or sampling inspection, what sampling conditions
should be set if it is sampling inspection, and the threshold value
as the acceptance criterium, are automatically setup in accordance
with the individual production order table from the production
information supervisory computer 35. The inspection data including
the rejection rate and inspection measurement values, is fed back
as performance data to the production information supervisory
computer 35 through the assembly line supervisory computer 31.
The labeling machine 39 attaches the label 15 to the cartridge
shell as being supplied from the assembling machine 38, for
example, in the way as disclosed in U.S. patent application Ser.
No. 08/620,345. The labels 15, each of which has the literal
indicia 16 indicating a film cartridge type, the bar code 17
representative of a cartridge ID number, and the alphanumeric
indicia of the cartridge ID number printed thereon, are arranged in
series on a releasing paper. The releasing paper with the labels 15
is wound into rolls, and the label rolls are supplied to the
labeling machine 39. The labels 15 are seriatim peeled off the
label roll, and attached to the cartridge shells 5 as the cartridge
shells 5 are supplied to the labeling machine 39. In this way, a
cartridge ID number is assigned to each cartridge shell 5 as a
serial number in accordance with the time sequence the cartridge
shell 5 is produced, or another regular sequence.
The production information supervisory computer 35 controls the
range of the cartridge ID numbers that are assigned to the
cartridge shells 5 being produced at present. Accordingly, the
individual production order table includes data of the cartridge ID
number range, and the production lot numbers of those label rolls
which hold those labels 15 having the cartridge ID numbers of the
designated range printed thereon, so that the labeling machine 39
is supplied with the corresponding label rolls. Prior to attaching
the label 15 to the cartridge shell 5, the cartridge ID number is
read from the label 15, and is compared with the cartridge ID
numbers indicated in the individual production order table.
After being labeled, the cartridge shell 5 is optically inspected
on the labeling position, and the cartridge ID number is read from
the bar code 17. If the labeling position or condition is improper,
the cartridge shell 5 is ejected from the line. The cartridge ID
number of the ejected cartridge shell 5 is processed as a missing
number, and is fed back to the production information supervisory
computer 35 through the assembly line supervisory computer 31.
The cartridge shells 5 are seriatim loaded and arranged on trays in
the same order as the labels 15 are attached. The trays are
transferred to and stored in the storage device 40. The tray can
hold the same number of finished cartridge shells 5 as the number
of shell halves 5a or 5b that is allocated to one tray in the
storage device 37. Accordingly, if there are rejected cartridge
shells, the number of cartridge shells 5 loaded on the tray is
reduced correspondingly. It is possible to use the same trays for
holding the cartridge shells 5 as used for holding the shell halves
5a or 5b.
Each time the tray with the finished cartridge shells 5 arrives at
the storage device 40, the tray ID number of the tray is read to be
fed in the assembly line supervisory computer 31. The assembly line
supervisory computer 31 checks the tray request signal that is
given to the assembling machine 38 at the start of assembling these
cartridge shells 5, and correlates the tray ID number of the tray
arrived at the storage device 40 with the tray ID numbers of the
trays used for carrying the shell halves 5a and 5b of these
cartridge shells 5. Also, the production lot numbers of other parts
supplied to the assembling machine 38, the production lot numbers
of the label rolls supplied to the labeling machine 39, the range
of the cartridge ID numbers used, and the cartridge ID numbers of
the rejected cartridge shells are associated with the tray ID
number of the tray in the storage device 40, as ID number data. To
the ID number data is added other data including a machine type
number of the cartridge assembly line 24, the production data, the
production conditions, the inspection conditions, the order number,
and the product short name of the film cartridge type. These data
pieces are sent to the production information supervisory computer
35 through the assembly line supervisory computer 31, and is stored
in the memory 35x.
In this way, the production information supervisory computer 35 can
monitor the tray ID numbers of all trays stored in the storage
device 40, and can trace based on the tray ID number the type of
the cartridge shells 5 loaded on each tray and their production
histories such as the order number of the production plan data, the
raw material type, the production conditions and the inspection
conditions which were used for producing these cartridge shells 5.
Accordingly, even after the shipment, it is possible to trace the
production history data of each individual photo film cartridge by
use of the production information supervisory computer 35 if only
the cartridge ID number is determined.
FIG. 6 shows the information supervisory operation over the entire
production process from the filmstrip manufacturing step to the
packing step into the corrugated cardboard boxes. The production
information supervisory computer 35 totally manages the line
supervisory computers of the respective manufacture lines,
including a slitter supervisory computer 42, the film winding line
supervisory computer 32, a packaging line supervisory computer 43
and a packing machine supervisory computer 44. The slitter
supervisory computer 42 receives an individual production order
table from the production information supervisory computer 35, and
displays the table on its monitor screen. The individual production
order table includes production lot numbers of those master rolls
which are suitable for the film cartridge type designated by the
production plan data. Among the stored master rolls, the master
rolls having the designated production lot numbers are selected one
after another, to be loaded in the slitter 21 by use of an
automatic vehicle and robotics.
The slitter supervisory computer 42 sends the slitter 21 condition
setup data, e.g. the feed out speed from the master roll,
inspection conditions for a surface inspector that is incorporated
into the slitter 21, and so forth. Then, the slitter 21 is actuated
to slit the master roll into the slit rolls having the same width
as the filmstrips 2 to produce. Then, the bar code labels
indicating the emulsion number, the master roll production lot
number and the slit number are attached to the outer end and the
reel of each slit roll. The bar code is read through an automatic
bar code reader or a manual operating handy bar code reader, and
the bar code data is sent to the slitter supervisory computer
42.
The film winding line supervisory computer 32 receives an
individual production order table which includes the emulsion
number, the master roll production lot number and the slit number
of the slit roll to be used in the film winding line 25. A handling
device such as a robot takes the designated slit rolls out of the
storage section 29, to be set one after another in a film feeder 45
of the film winding line 25. If there remains a trailing portion of
a preceding slit roll in the film feeder 45, the outer end of the
newly set slit roll is spliced to the trailing end of the preceding
slit roll. The bar code of the new slit roll is read to identify
the slit roll. Simultaneously, performance data about the preceding
slit roll is sent to the production information supervisory
computer 35 through the film winding line supervisory computer 32.
The film winding line supervisory computer 32 controls the film
winding line 25 so as to operate under the conditions designated by
the individual production order table from the production
information supervisory computer 35.
A perforator 46 forms the perforations 2a through the continuous
strip from the slit roll in the arrangement as shown in FIG. 1. The
number of perforations 2a is defined by the number of available
exposures of the film cartridge type to produce. Since the data of
the available exposure number is included in the individual
production order table, the film winding line supervisory computer
32 designates the number of perforations 2a to form by the
perforator 46.
The continuous strip moves past the perforator 46 to a side-printer
48, wherein side-printing data is optically printed as latent
images on the side of the continuous strip. The side-printing data
includes bar codes of the film ID number of each individual
filmstrip 2 to be made from the continuous strip, alphanumeric
indicia of the film ID number, frame serial numbers, the product
short name, manufacturer name, and so forth. The film data except
the film ID number can be determined based on the product short
name when the production plan data is input into the production
information supervisory computer 35. The film ID numbers must be
coincide with the cartridge ID numbers given to the corresponding
cartridge shells 5 in the cartridge assembly line 24.
Therefore, when the production information supervisory computer 35
prepares the common production order table, the production
information supervisory computer 35 checks the range of the
cartridge ID numbers used, which is included in the ID number data
received from the assembly line supervisory computer 31, to
determine the range of the film ID numbers for the side-printing in
correspondence with the range of the cartridge ID numbers printed
on the labels 15 attached to the cartridge shells 5 in the assembly
line 24. It is of course possible to determine the range of the
film ID numbers first, and designate the range of the cartridge ID
numbers and corresponding labels.
The range of the film ID numbers thus determined is stored along
with the order number of the production plan data in the production
information supervisory computer 35, and is written in the
individual production order table for the film winding line
supervisory computer 32. The side-printer 48 makes the
side-printing in accordance with this table.
Each time the side-printer 48 prints a film ID number, the film ID
number is fed back to the film winding line supervisory computer 32
together with other kinds of the side-printing data, and is
collated with the film ID number designated by the individual
production order table. The film winding line supervisory computer
32 associates other data obtained beforehand, such as the emulsion
number, the master roll production lot number and the slit number,
with the film ID number, and sends those data pieces to the
production information supervisory computer 35, to be stored in the
memory 35x.
After the side-printing, a cutter 49 cuts the continuous strip into
the individual filmstrips 2. Since the continuous strip is advanced
at a constant speed in the film winding line 25, and the advanced
length is measured through a rotary encoder, it is possible to
actuate the cutter 49 when the advanced length reaches a length
determined depending upon the number of available exposures of the
individual filmstrips 2 to produce. The production conditions for
the cutter 49 are also written in the individual production order
table of the film winding line supervisory computer 32.
At the cutting, the shapes of the leading and trailing ends of the
filmstrips 2 are formed, and the fastening hole 3 and the hooking
holes 4 are punched through the trailing end. In the film winding
line 25, the trailing end of the filmstrip 2 is headed toward the
cartridge shell 5 which is placed in a film winder 50. The
cartridge shells 5 are supplied to the film winder 50 tray by tray,
and the tray ID number is read to be entered in the production
information supervisory computer 35 through the film winding line
supervisory computer 32.
Since the production information supervisory computer 35 stores the
cartridge ID numbers and the production history data of the
cartridge shells 5 loaded on each tray in association with its tray
ID number, the production information supervisory computer 35 can
trace and verify not only the range of the cartridge ID numbers of
the supplied cartridge shells 5, but also the order number for
these cartridge shells 5 and the production lot numbers of the
respective parts of the cartridge shells 5.
Immediately before the cartridge shell 5 is seriatim placed in the
film winder 50, the cartridge ID number of each cartridge shell 5
is read through the bar code 17 on the label 15. The cartridge ID
number is sent to the film winding line supervisory computer 32, as
soon as it is read from the cartridge shell 5. On the other hand,
the film winder 50 is synchronized with the side-printer 48 such
that the cartridge ID number that has just been read from the
cartridge shell 5 coincides with the film ID number that the
side-printer 48 is about to print on the continuous strip in a
length allocated to the next filmstrip 2 to produce. Accordingly,
the film winding line supervisory computer 32 can collate the
cartridge ID numbers with the film ID numbers immediately before
the side-printer 48 prints the film ID number. The film winder 50
is also synchronized with the cutter 49 such that the filmstrip 2
having the film ID number printed thereon is combined with the
cartridge shell 5 having the same cartridge ID number as this film
ID number.
The cartridge ID numbers and the film ID numbers are also sent to
the production information supervisory computer 35, to be collated
with each other, and with the cartridge or film ID numbers written
in the production information supervisory computer 35, which are
designated by the production plan data to the film cartridge type
to produce.
After the production information supervisory computer 35 confirms
that the cartridge ID number is proper, the production information
supervisory computer 35 allows the side-printer 48 to effect
side-printing in accordance with the side-printing data that the
side-printer 48 receives from the production information
supervisory computer 35 through the film winding line supervisory
computer 32. In this way, the cartridge ID number is collated with
the film ID number immediately before the filmstrip 2 is wound into
the cartridge shell 5, so that it is possible to prevent
incoincidence between the cartridge ID number and the film ID
number of the same photo film cartridge with high reliability.
Although there may be rejected cartridge shells 5 at the inspection
processes on the cartridge assembly line 24, since their cartridge
ID numbers are stored as the missing numbers in the production
information supervisory computer 35, if any cartridge ID number,
e.g. "100,002", is missing in the cartridge ID number data read
from the cartridge shells 5 supplied to the film winder 50, the
production information supervisory computer 35 can confirm whether
it should be processed as the missing number. If so, the production
information supervisory computer 35 prohibits the corresponding
film ID number "100,002" from being used, so that the side-printer
skips that film ID number. Data of the missing number is also
stored as performance data in the production information
supervisory computer 35.
The film winder 50 secures the trailing end of the filmstrip 2 to
the spool 6 of the cartridge shell 5, and then rotates the spool 6
to wind up the filmstrip 2 fully into the cartridge shell 5, and
then closes the light shielding door 7, thereby completing the
photo film cartridge. Since the production history data of the
filmstrip 2 such as the emulsion number, the master roll production
lot number and the slit number, is previously known, the production
history data of the filmstrip 2 is stored with the production
history data of the combined cartridge shell 5 in the production
information supervisory computer 35 in association with the film ID
number or the cartridge ID number.
The photo film cartridges from the film winder 50 are loaded on
trays each can hold a predetermined number of cartridges, and these
trays are stored in a storage section 51, in the same way as in the
storage device 40 of the assembly line 24. The trays are also
provided with respective tray ID numbers, which are read and sent
to the film winding line supervisory computer 32. The film winding
line supervisory computer 32 correlates the tray ID number with the
ID numbers used for the photo film cartridges, i.e. the cartridge
ID numbers or the film ID numbers, loaded on the tray having that
ID number, and with the missing number data and the production
history data of these photo film cartridges. The film winding line
supervisory computer 32 feeds the data correlated with the tray ID
number back to the production information supervisory computer 35.
Therefore, it is possible to retrieve, based on the tray ID number,
data about the photo film cartridges stored in the storage section
51, such as their ID numbers, the film cartridge type, the
production histories of their filmstrips 2 and their cartridge
shells 5.
The photo film cartridges stored in the storage section 51 are sent
to the packaging line 27 tray by tray, wherein each photo film
cartridge is cased in the plastic case 11 by a plastic casing
apparatus 52, and is packaged with the casket 13 by a packaging
apparatus 53. The packaging line 27 is under the control of the
packaging line supervisory computer 43, which is under the control
of the production information supervisory computer 35, in the same
way as other line supervisory computers. The production information
supervisory computer 35 designate the production lot numbers of the
plastic cases 11 in the individual production order table. The
plastic casing apparatus 52 feeds back the production lot numbers
of the used plastic cases 11 to the production information
supervisory computer 35 through the packaging line supervisory
computer 43.
The indicia 18 and the bar code 19b that indicate a film cartridge
type are previously printed on the casket 13. The bar code 19a
indicating a package ID number is printed by a printer 55 which is
disposed in a path from a casket supplier 54 to the packaging
apparatus 53. The printer 55 may be an ink-jet printer, a Laser
printer, or a thermal transfer printer.
The package ID number is designated by the production information
supervisory computer 35 when the production information supervisory
computer 35 receives the production plan data. The printer 55 is
actuated to print the designated package ID number onto the casket
13 after the packaging line supervisory computer 44 identifies the
package ID number with the cartridge ID number of the photo film
cartridge to be packaged in that casket 13. It is alternative
possible to print the bar code 19a in advance in each casket 13,
and store the range of the used package ID number in the production
information supervisory computer 35 in accordance with the
production lot numbers of the caskets 13, and read the bar code 19a
by a bar code reader which takes place of the printer 55, so as to
collate the cartridge ID number with the package ID number.
The package ID number on the casket 13 allows to retrieve the whole
production history data of the photo film cartridge contained
therein based the package ID number even after the photo film
cartridge is shipped for sale. If any photo film cartridges on sale
are found to be defective, it is possible to recover those having
the same production histories as the defective ones without the
need for opening their caskets 13. The package ID numbers are not
necessarily identical with the respective cartridge ID numbers, if
only the package ID number and the cartridge ID number are
correlated with each other and stored in the production information
supervisory computer 35.
The photo film cartridge packaged with the casket 13 are forwarded
to a wrapping apparatus 56, and are wrapped up in cellophane sheet
in groups, e.g. in groups of ten. Thereafter, parcels of the
wrapped photo film cartridges are stacked up in a storage section
57 and then transferred to a packing line 58, automatically through
robotics or the like. The packing line 58 consists of a cardboard
box supplied 59, a printer 60, and a packing apparatus 62, and is
controlled by the packing line supervisory computer 44. The packing
apparatus 62 packs several parcels of the wrapped ten photo film
cartridges in corrugated cardboard boxes. In this way, for example,
a thousand photo film cartridge packages are packed in one box. The
printer 60 prints a box ID number on each box in the form of a bar
code. The printer 60 may be an inkjet printer, a Laser printer and
a thermal transfer printer.
The box ID numbers are also designated by the production
information supervisory computer 35, such that one box ID number is
allocated to a series of package ID numbers which are printed on
the thousand packages contained in one corrugated cardboard box.
The relationship between the box ID number and the package ID
number is stored in production information supervisory computer 35.
Therefore, it is possible to retrieve based on the box ID number
the range of the package ID numbers of the packages contained in
each corrugated cardboard box. It is also possible to determine
based on the package ID number which box contains a particular
photo film cartridge. In this way, it is possible to trace the each
individual product also during the transportation.
Now the overall construction and operation in the film winding line
25 will be described with reference to FIG. 7. When a slit roll 63
is set in a given position and a start signal is entered in the
film winding line supervisory computer 32, the process controller
32a actuates a motor 64 and feed-out rollers 65 of the film feeder
45, to start feeding a continuous strip 69 from the slit roll 63. A
bar code reader 66 reads the bar code on the label put on the outer
end of the continuous strip 69, so that data of production history
of the slit roll 63 is entered through the process controller 32a
into the film winding line supervisory computer 32. The film
winding line supervisory computer 32 collates the production
history data of the slit roll 63, such as the emulsion number, the
master roll production lot number and the slit number, with those
designated by the individual production order table from the
production information supervisory computer 35.
The motor 64 also rotates feed rollers of a transport path of the
continuous strip 69, to advance it to the perforator 46 first. The
process controller 32a controls the operation of the perforator 46,
while monitoring the advanced length of the continuous strip 69
through a measuring roller 67. So the perforator 46 forms the
perforations 2a through the continuous strip 69 in accordance with
the number of available exposures assigned to the film cartridge
type designated by the individual production order table.
Thereafter, the continuous strip 69 is fed to a printer drum 68. A
printer head 70 of the side-printer 48 is arranged to face the
emulsion surface of the continuous strip 69 around the printer drum
68. The printer head 70 has an array of photo emission diodes
extending across the continuous strip 69, and a condenser lens
system for forming images on the side portions of the continuous
strip 69. The process controller 32b controls the side-printer 48.
The printer drum 68 is accompanied by an rotary encoder 71 to
measure the advanced length of the continuous strip 69 at each
side-printing. The measured length is fed back to the process
controller 32b. The side-printer 48 may preferably be those
disclosed in JPA 6-130548.
Thus, the continuous strip 69 is recorded with side-printing data
as photographic latent images. The side-printing data includes the
product short name, manufacturer name, frame serial numbers, bar
codes of the film ID number of each individual filmstrip 2 to be
made from the continuous strip, alphanumeric indicia of the film ID
number. The side-printing data is included in the individual
production order table which the film winding line supervisory
computer 32 receives from the production information supervisory
computer 35. After each side-printing, the side-printing data
having been printed is fed back to the production information
supervisory computer 35 through the film winding line supervisory
computer 32, and is stored as performance data.
The continuous strip 69 with the side-printing data recorded
thereon is fed to the cutter 49. The cutter 49 consists of a
movable edge and a stationary edge, to cut the continuous strip 69
into individual filmstrips 2 whose length is designated by the
process controller 32a according to the number of available
exposures assigned to one filmstrip 2. The advanced length of the
continuous strip 69 measured by the rotary encoder 71 is also sent
to the process controller 32a through the process controller 32b,
so that the motor 64 pauses while the cutter 49 performs cutting.
Simultaneously with the cutting, the cutter 49 shapes the leading
end of the just cut filmstrip 2 and the trailing end of the
filmstrip 2 next to be cut off the continuous strip 69, and punches
the fastening hole 3 and the hooking holes 4 through the trailing
end. The filmstrip 2 is then transported toward the film winder 50
with the trailing end in the lead.
There are disposed an upper stationary guide plate 74a and a
downward movable guide plate 74b between a first pair of feed
rollers 72 and a second pair of feed rollers 73. The movable guide
plate 74b includes two pivotal flaps whose respective axes extend
in the film transporting direction, so that the guide plate 74b
serves as a door to open or close an entrance of a film loop
chamber 75. When the trailing end of the filmstrip 2, that is, a
front end in the film transporting direction, reaches the second
pair of feed rollers 73, the movable guide plate 74b is opened to
form a loop of the filmstrip 2 in the film loop chamber 75. The
first pair of feed rollers 72 is driven by the motor 64, so that
they stops rotating while the cutter 49 performs cutting. The
second pair of feed rollers 73 are driven by another motor 76 which
is under the control of the process controller 32c for the film
winder 50. The film loop chamber 75 is provided for absorbing the
difference in the transport speed between the first pair of feed
rollers 72 and the second pair of feed rollers 73.
A another pair of film guide plates 83 is disposed downstream from
the second pair of feed rollers 73. First and second infrared
reflective photo sensors 77 and 78 are disposed before and behind
the film guide plates 83, respectively, to output a low level
signal to the process controller 32c while they receive light
reflected from the continuous strip 69, and a high level signal
while no light is received. Thus, the process controller 32c can
determine when the ends of the filmstrip 2 pass under the
respective photo sensors 77 and 78. The lower one of the film guide
plates 83 is also movable upon a command from the process
controller 32c, so as to eject defective filmstrips 2 or fragments
of filmstrip 2 from the film winding line 25 through a chute
80.
The process controller 32c also controls a film inserter 79 of the
film winder 50. The film inserter 79 is disposed at a first station
ST1 of a turn table 82 at which an empty cartridge shell 5 is
standby. At the first station ST1, the spool 6 of the empty
cartridge shell 5 is engaged with a not-shown drive shaft that is
driven by a motor 81, and the light shielding door 7 is engaged
with a not-shown door drive shaft. First the spool 6 is set to a
given angular position, and the film inserter 79 inserts the
trailing end of the filmstrip 2 through the film port 9 to secure
the trailing end to the spool 6. The process controller 32c
controls the motor 81 such that the motor 81 rotates the spool 6 in
a winding direction at a high speed when the loop in the film loop
chamber 75 reaches a predetermined length after the trailing end of
the filmstrip 2 is secured to the spool 6.
Thereafter when the first photo sensor 77 detects the leading end
of the filmstrip 2, i.e. a rear end in the film transporting
direction, the process controller 32c changes the speed of the
motor 81 to a lower value. Thereafter when the second photo senor
78 detects the leading or read end of the filmstrip 2, the motor 81
is further driven to make a predetermined number of rotations, and
is then deactivated. The number of further rotations is determined
to be enough to wind up the entire length of the filmstrip 2 into
the cartridge shell 5. Instead of controlling the number of
rotation, it is possible to determine the time duration from the
rear end detection by the second photo sensor 78 to the stop of the
motor 81.
Since the diameter of the roll of the filmstrip 2 fully wound on
the spool 6 increases with the increase of its length, i.e., the
number of available exposures, the time duration or the number of
further rotation should be determined based on the shortest
filmstrip 2 to produce. Thereby, any type of filmstrip 2 can be
wound up completely in the cartridge shell 5 by use of a common
control sequence.
The turn table 82 is rotatable about an axle 82a, and is driven to
makes a half rotation intermittently by a motor 85 which is
controlled by a process controller 32d. The turn table 82 is
provided with two holders for holding the cartridge shells 5. At a
second station ST2, which is disposed opposite from the first
station ST1 in the radial direction, a put-in/put-out mechanism 86
puts out the cartridge shell 5 having the filmstrip 2 wound up
therein from the turn table 82, and puts the empty cartridge shells
5 supplied from the cartridge assembly line 24 in one of the
holders. The put-in/put-out mechanism 86 is controlled by the
process controller 32d. Each time the cartridge shell 5 is put on
the turn table 82 at the second station ST2, a bar code reader 87
reads its cartridge ID number from the bar code 17 of the label 15,
and sends the ID number to the process controller 32d.
The process controller 32d sends the cartridge ID number to the
film winding line supervisory computer 32. The film winding line
supervisory computer 32 then collates the cartridge ID number with
a film ID number which the side-printer 49 is about to print. This
film ID number is assigned to the next filmstrip 2 to be cut off
from the continuous strip 69 following the filmstrip 2 that is
being wound into the cartridge shell 5 at the first station ST1.
Since the cartridge shell 5 just put in on the turn table 82 at the
second station ST2 is determined to be combined with this next
filmstrip 2, the collation of the cartridge ID number with the film
ID number prior to the side-printing of the film ID number ensures
preventing incoincidence between the film ID number and the
cartridge ID number of the same photo film cartridge.
The cartridge ID number of each supplied cartridge shell 5 may be
read at another position. For example, since the cartridge shells 5
are seriatim supplied from a supply stacker 89 to the turn table
82, and a designated series of film ID numbers are previously sent
to the film winding line supervisory computer 32, it is possible to
read the cartridge ID number at a predetermined position on the
supply stacker 89, and collate it with one of the series of film ID
numbers that corresponds in the order.
When the film winding at the first station ST1 is accomplished, the
light shielding door 7 is closed, and the turn table 82 is rotated
through 180 degrees, to move the cartridge shell 5 with the
filmstrip 2 to the second station ST2. At the same time, the empty
cartridge shell 5 is moved to the first station ST1, and the spool
6 of the empty cartridge shell 5 is engaged with the notshown drive
shaft, and is set into the given angular position. Also, the light
shielding door 7 is engaged with the not-shown door drive
shaft.
The light shielding door 7 is open when the cartridge shell 5 is
supplied to the second station ST2, and is maintained open in the
first station ST1 unless the film winding step is complete.
When the cartridge shell 5 with the filmstrip 2 wound therein is
moved to the second station ST2, the process controller 32d
actuates the put-in/put-out mechanism 86 to transfer it from the
turn table 82 to a stacker 88. A not-shown bar code reader reads
the cartridge ID number from the transferred cartridge shell 5, and
sends it as performance data to the process controller 32d. The
performance data is stored in production information supervisory
computer 35. Thereafter, the put-in/put-out mechanism 86 puts out
the next empty cartridge shell 5 from the supply stacker 89 and put
it in the emptied holder of the turn table 82.
Since the printer head 70 consists of an array of photo emission
diodes, a print pattern that is printed on each filmstrip 2 through
the printer head 70 can be determined based on current patterns and
timings of drive currents applied to the photo emission diode.
Based on the print pattern thus detected, it is possible to confirm
the film ID number that is actually printed by the side-printer 48.
Therefore, it is possible to collate the actually printed film ID
number with the cartridge ID number of the cartridge shell 5
containing that filmstrip 2, or with the film ID number that is
designated by the film winding line supervisory computer 32.
If any malfunction happens in the film winder 50, the
put-in/put-out mechanism 86 ejects the defective photo film
cartridge through a chute 90. The cartridge ID number of the
ejected photo film cartridge 5 is read by a not-shown shown bar
code reader, and is sent to the film winding line supervisory
computer 32, to be stored as performance data in the production
information supervisory computer 35.
To the supply stacker 89, the cartridge shells 5 are transported
tray by tray from the storage device 40. At that time, the tray ID
number is read to be sent to the production information supervisory
computer 35 through the film winding line supervisory computer 32.
Since the production information supervisory computer 35 stores the
cartridge ID numbers of the cartridge shells 5 in association with
the tray ID number of the tray that carries the cartridge shells 5,
and the film winding line supervisory computer 32 receives the
individual production order table that designates the appropriate
range of tray ID numbers and cartridge ID numbers, those cartridge
shells 5 having inappropriate ID numbers are prevented from being
supplied to the film winding line 25.
As an alternative method for collating the cartridge ID number with
the film ID number, the labeling machine 39, which is disposed in
the cartridge assembly line 24 in the above described embodiment,
may be disposed in the supply stacker 89 instead, as is shown by
phantom lines in FIG. 7. In that case, the individual production
order table for the film winding line supervisory computer 32
should include the production lot numbers of the label rolls whose
labels have the cartridge ID numbers corresponding to the film ID
numbers to be printed. Each time one of the designated film ID
numbers is printed by the side-printer 48, the label 15 having the
corresponding cartridge ID number is attached to the cartridge
shell 5 in the supply stacker 89, that is determined to be combined
with the filmstrip 2 having that film ID number.
It may be possible to check the film ID number printed on the
filmstrip 2, and then print a corresponding cartridge ID number on
the label is immediately before or after it is attached to the
cartridge shell 5. However, in this case, if the cartridge ID
number printed on the label 15 is not dried or fixed sufficiently
before the cartridge shell 5 is moved onto or out of the turn table
82, the cartridge ID number is blurred or stained. The blurred or
stained cartridge ID number is a certain problem especially for IX
240 type photo film cartridge whose cartridge ID number need to be
automatically readable in photo-printing process.
The inspection process in the film winding line 25 will now be
described. If any trouble that damages the quality of film happens
in the slitter 21, or if any defective portion is detected by the
surface inspection on the continuous strips formed by the slitter
21, the damaged position or the defective portion can be determined
as a length or distance from the end of the continuous strip of the
slit roll. The distance data is stored along with the master roll
production lot number and the slit number of the slit roll having
the defective portion in the production information supervisory
computer 35, for use as defection data.
When it is determined based on the bar code read through the bar
code reader 66 that the slit roll 63 set in the film winding line
25 has a defective portion, the cutter 49 cut off the defective
portion to eliminate from the film winding line 25. Since the
advanced length of the continuous strip 69 in the film winding line
25, which corresponds to the length unwound or withdrawn from the
slit roll 63, is monitored through the measuring roller 67 and the
rotary encoder 71, it is possible to calculate based on the
defection data which of the filmstrips 2 will include the defective
portion.
When the continuous strip 69 has been withdrawn from the slit roll
63 by the length indicated by the defection data, the production
information supervisory computer 35 sends an elimination command to
the film winding line supervisory computer 32, whereupon the
side-printer 48 skips printing or prints the same side-printing
data as printed on the preceding filmstrip 2. Thereafter when it is
determined that the defective portion is moved past the cutter 49,
the continuous strip 69 stops being transported, and the cutter 49
is activated. The film fragment thus cut off from the continuous
strip 69 is ejected through the chute 80. The ejection of the
defective portion is also stored as performance data in the
production information supervisory computer 35 through the film
winding line supervisory computer 32.
In the same way as for the slit rolls 63, any detective portions of
the master rolls, which may be caused by bad coating or drying of
the emulsion, can be eliminated during the slitting process or the
winding process, on the basis of defection data stored in
association with the master roll production lot number in the
production information supervisory computer 35.
Since the filmstrip 2 of IX 240 type is provided with a transparent
magnetic recording layer on the back surface from the emulsion
surface, the film winding line 25 may also check the magnetic
properties of the magnetic recording layer. In that case, it is
preferable to classify the quality of the magnetic recording layer,
for instance, into three ranks, and store the rank data in the
production information supervisory computer 35. Thus, it is
possible to store the rank data of each individual filmstrip 2 in
association with the film ID number.
According to the above described production information managing
method, the production information supervisory computer 35 stores
all data used for and obtained during the production of the photo
film cartridges of all types. That is, the production information
supervisory computer 35 stores the production plan data, the common
production order table of each film cartridge type, and the
individual production order tables individually sent to the line
supervisory computers. The production information supervisory
computer 35 also correlates the production lot number, the
production date and the type of raw material of each part of the
individual photo film cartridge with the film ID number and the
cartridge ID number on the basis of the tray ID number assigned to
each part, and stores the production history data of each part in
association with the film ID number and the cartridge ID number,
which are identical or correlated with each other. Accordingly, it
is possible to retrieve all production information and quality
information about the individual photo film cartridge based on its
cartridge ID number or film ID number even after the photo film
cartridge comes on the market.
Furthermore, according to the production information managing
method of the present invention, it is possible to store the date
and the situation of disorders that happened in some production
facilities, in the form of code data along with other production
history data in the production information supervisory computer 35.
Thereby, it is possible to trace when and where the disorder
happened, and correlate these information with the tray ID number,
as well as the film ID number or the cartridge ID number.
In addition, since environments in the factory have large effect on
the quality of produced photo film, temperature, humidity and
cleanness of the respective production facilities should be
maintained in proper conditions. For example, if the temperature
and the humidity are improper, photographic properties of the
emulsion surface would be unsatisfactory. The curling tendency of
the photo film varies with the variation of the temperature and the
humidity, resulting in poor physical properties of the filmstrip
inside the cartridge shell. Especially in IX 240 type, the poor
physical properties of the filmstrip hinder the leader-advancing
function. Since emulsion swarfs and film swarfs are resulted from
the slitting or cutting, the swarfs can be deposited on the
emulsion surface if the cleanness of the circumstance is
deteriorated. Therefore, it is preferable to measure the
environmental conditions in the production facilities, and feed
measurement data back to the respective line supervisory computers
through the process controllers, for use in controlling the
environmental conditions. It is also preferable to store the
measurement data in the production information supervisory computer
35.
It is preferable to periodically monitor operational conditions of
the production facilities, such as variations in the power supply
voltage, in the air pressure supplied to an air cylinder device for
actuating the robotics, and in the voltage supplied to an
ultrasonic welding apparatus which is used for securely mating the
shell halves 5a and 5b, and store the data about these conditions
in the production information supervisory computer 35 through the
process controller and the respective line supervisory computers.
Because even inevitable slight variations in the operational
conditions as above may have a certain effect on the quality of the
products, to say nothing of accidental or huge variations that can
be caused by lightning.
Although the present invention has been described with respect to
the embodiment shown in the drawings, the present invention is
applicable not only to IX 240 type photo film cartridge, but also
to any other type photo film cartridges including the conventional
ISO 135 type. The present invention is adaptable to the production
facilities for sheet films or sheet film packs each containing a
plurality of sheet films.
Thus, the present invention should not be limited to the above
described embodiments but, on the contrary, various modifications
may be possible to those skilled in the art without departing from
the scope of claims attached hereto.
* * * * *